Melt processable composition from recycled multi-layer articles containing a fluoropolymer layer

ABSTRACT

The invention relates to a composition that has been obtained by the melt-process recycling of one or more multi-layer articles, where the multi-layer articles are composed of at least one melt-processible fluoropolymer layer. The composition of the invention is a compatible blend of the different layers from the multi-layer articles. The other layers of the multi-layer articles are also melt-processible, and include one or more layers chosen from: a) a melt-processible fluoropolymer of a different composition, b) a non-fluoropolymer, and c) a barrier layer. The composition is useful for forming an article in a melt-process operation. The composition may be used by itself, may be blended with other virgin or recycled materials, or may be used at low levels with melt-processible polymers as a process aid.

FIELD OF THE INVENTION

The invention relates to a composition that has been obtained by themelt-process recycling of one or more multi-layer articles, where themulti-layer articles are composed of at least one melt-processiblefluoropolymer layer. The composition of the invention is a compatibleblend of the different layers from the multi-layer articles. The otherlayers of the multi-layer articles are also melt-processible, andinclude one or more layers chosen from: a) a melt-processiblefluoropolymer of a different composition, b) a non-fluoropolymer, and c)a barrier layer. The composition is useful for forming an article in amelt-process operation. The composition may be used by itself, may beblended with other virgin or recycled materials, or may be used at lowlevels with melt-processible polymers as a process aid.

BACKGROUND OF THE INVENTION

The worldwide consumption of plastics is around 400 billion pounds ayear—with only about 12% being recycled. There has been a movement toincrease the level of plastics recycling to reduce landfill usage. Whilemunicipal waste has traditionally been the main target for recycling,other type of plastic waste such as those generated by industry isgaining more attention. Some industries, such as the biopharmaceuticalsector, are more sensitive to the life cycle of their waste. In thismarket, recyclability gains even more importance for the products thatare designed for one-time use.

The majority of the recycled plastics are single layer bottles or filmsmade from PET, HDPE, PVC or LDPE. Mixed plastic waste is generallyseparated into the different chemical species due to a lack ofcompatibility between many of these materials—resulting in poor blendproperties if blended. In general, recycling of materials containingbarrier layers such as epoxies, ethylene vinyl alcohol (EVOH) orpolyamides is not practiced, mainly due to compatibility issues.

In addition to the single-layer polymer products, many multi-layerpolymer articles exist. The use of multiple layers allows one to takeadvantage of the properties of each polymer—such as chemical resistance,permeation resistance, weatherability, and physical properties.

It is critical to performance that the various layers of a multi-layerarticle adhere to one another. This adherence can occur in many ways,including: compatibility or miscibility of the polymers, with themulti-layer formation process generally involving heat and/or pressure;the use of a tie layer (reactive or non-reactive) or adhesive; a surfacetreatment of one or both surfaces to increase interactions, such as bycorona treatment, plasma treatment, chemical etching or even physicalabrasion; or by adding functionality into one or both layers that canreact covalently with the other layer under processing conditions.

There is a trend in the pharmaceutical industry to reduce the price ofthe medicine, move towards individualized drugs and reduce the time fornew drug development. Moreover, the FDA is enhancing and modernizing thedrug production regulations with a push towards improved riskmanagement. The general outcome of these inputs is a move towardsadoption of single use manufacturing systems. These systems aretypically made completely from plastics and designed to replacestainless steel vessels, pipes and components for production of drugsand batch processed medicines. Currently, several companies manufacturesystems with capacities from 1 L to 10,000 L for cell growth, bufferpreparation and drug synthesis. These systems typically include bags,tubes, fittings, stirrers and other components. Each of these articleshas specific requirements that would necessitate a multilayer structurein the design of some components. It is estimated that several millionpounds of plastics will be used in these systems in the next severalyeas. The pharmaceutical industry is very particular about the lifecycle of their products and is very interested in minimizing thelandfill and/or incineration of these single use systems. Moreover, someEuropean regulation bodies are putting emphasis on the life cycle ofthese disposable systems. Therefore, there is a need to have amanufacturing system that would perform the required functional tasksand be recyclable after it is discarded. Currently the disposablemanufacturing systems are incinerated.

Recycling of a multi-layer material (article or scrap) presents specialissues, since the layers cannot be easily separated before recycling.First, the whole multi-layer article must be designed to meet specificrequirements of high purity, and resistance to permeation of gases andliquids. In the biopharmaceutical industry there is also a need for asurface that resists protein adhesion. Then, in addition, the articlemust also be capable of being melt blended into a usable article. Thepolymers in a recyclable multi-layer material must be compatible at botha macro-level and a micro-level.

Compatibility in the polymer adhesion context is represented by lowinterfacial tension. Specifically the polar component of the surfacetension plays a major role in the peeling strength and the work ofadhesion between polymers. Typically, the greater the polaritydifference, the greater will be the interfacial tension. In addition tothe interfacial tension, other factors such as processing parameters andtooling design can affect the peeling strength.

On a macro-compatibility level, the layers of the multi-layer structureneed to be compatible only on their surfaces. However, during recycling,the polymers are melt blended in the bulk and must also be compatible ata micro level when the individual polymer chains contact each other. Inpolymer blends, the important mechanical, transport and opticalproperties depend on the size of the polymer phases, which in turn isdictated by viscosity ratio, mixing intensity in the extruders andcompatibility of the components. In many instances, interfacial areabetween the phases is the weak point in the polymer bland. In thesecases, the failure starts from this area and progresses through the bulkof the material. Strength of this interface, to a great extent isdetermined by the compatibility of the polymers in the blend. Therefore,a compatible blend would have good surface and processing aspect,reduced phase size, strong domain interface and good melt behavior. Forpolymer blends compatibility is represented by Flory interactionparameter. It can be shown that Flory interaction parameter andinterfacial tension are related to each other.

Many multilayer films do not produce compatible polymer blends. Thesedemonstrate chemical bonding or compatibility at the interface, to allowproduction of a multilayer film structure, but not micro-scalecompatibility that is good enough for an intimate blend with propermorphology and phase size. In multilayer films in which surfaces of thepolymers are modified for adhesion, the bulk of the layers would remainincompatible—resulting in a poor recycled blend.

In multilayer films using a tie layer or adhesive, the tie layer may actas a compatibilizer. However, the amount of tie layer generally is notsufficient to provide total surface coverage of the minor phase. Oftenthe tie layer simply forms a separate phase inside the most compatiblepolymer in the blend—resulting in large incompatible polymer domains.

Functionalized or cross-linked layers may negatively affect viscosity ofthe blend, making it difficult to reprocess. Ideally, recyclablemultilayer films are those in which all of the layers are reasonablycompatible with each other. The recycle of many multi-layer filmscontaining only low-performance plastics is generally not worth therecycling cost, and may not produce melt-blends from which usefularticles can be formed.

There is a need for multilayer structures designed to have a) excellentphysical, chemical, purity, permeation resistance and purity useful inhigh purity applications, b) layers that adhere well together in theapplication, and c) are capable of being recycled into usefularticles—where the layers that are compatible in a melt blend and theblend has good physical and processing properties.

Compatibility is especially problematic when at least one layer of amultilayer structure is a fluoropolymer. Fluoropolymers, by theirnature, are incompatible with, and difficult to adhere to mostsubstances.

Surprisingly, Applicant has now developed multilayer structures in whichthe layers adhere well, have the excellent properties for use in highpurity applications, and are capable of being recycled. One additionaladvantage of recycling the multilayer structures of the invention isthat fluoropolymers, and other polymers used in these types ofstructures, can be relatively expensive materials, and the articlesformed from the recycled blend can receive a performance benefit fromthe special properties of the fluoropolymer and other high-performancerecycled polymer layers.

SUMMARY OF THE INVENTION

The invention relates to a melt processible polymer composition having acompatible melt blend formed from one or more recycled multi-layerarticles having at least one melt-processible fluoropolymer layer.

The invention further relates to an article formed from the compositionby a melt process.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a micrograph showing the compatibility of a melt-blend of amulti-layer film of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention relates to a multi-layered article containing at least onemelt-processible fluoropolymer layer, which can be recycled into auseful article.

By “multi-layer article”, as used herein is meant an article, film orsheet having two or more layers. The article may consist of 2, 3, 4, 5,6 or more layers adhered together. Tie layers and adhesive layers may bepart of the structure, or the different layers may adhere togetherwithout tie-layers or adhesives.

Fluoropolymer Layer

One or more layers of the multi-layer structure are melt processiblefluoropolymers. In one embodiment, more than one layer is afluoropolymer.

The term “fluoromonomer” or the expression “fluorinated monomer” means apolymerizable alkene which contains at least one fluorine atom,fluoroalkyl group, or fluoroalkoxy group attached to the double bond ofthe alkene that undergoes polymerization. The term “fluoropolymer” meansa polymer formed by the polymerization of at least one fluoromonomer,and it is inclusive of homopolymers, copolymers, terpolymers and higherpolymers which are thermoplastic in their nature, meaning they arecapable of being formed into useful pieces by flowing upon theapplication of heat, such as is done in molding and extrusion processes.Fluoropolymers useful in the present invention are those that are meltprocessable. Some examples of fluoropolymers that are melt processableinclude, but are not limited to polyvinylidene fluoride and it'scopolymers (PVDF and co-PVDF), ethylene tetrafluoroethylene (ETFE),ethylene chlorotrifluoroethylene (ECTFE), fluorinated ethylene propylene(FEP), tetrafluoroethylene-perfluorovinyl propyl ether (PFA), and anycombination of monomers where at least one of them is fluorinated. Thesecould also include EFEP (ethylene, hexafluoropropylene,tetrafluoroethylene), PVDF copolymerized with hexafluoropropylene,perfluorovinyl methyl or propyl ether, ethylene, tetrafluoroethylene,vinyl fluoride, vinyl trifluoride, ethylene, etc., as well as functionalmonomers such as maleic anhydride, glycidyl methacrylate, etc. Somefluoropolymers that are not part of the invention due to poor meltprocessability include, but are not limited to, propylenechlorotrifluoroethylene (PCTFE), polytetrafluoroethylene (PTFE) andpolyvinyl fluoride (PVF).

Preferred fluoropolymers of the invention are the homopolymer made bypolymerizing vinylidene fluoride (VDF), and copolymers, terpolymers andhigher polymers of vinylidene fluoride wherein the vinylidene fluorideunits comprise greater than 70 percent of the total weight of all themonomer units in the polymer, and more preferably, comprise greater than75 percent of the total weight of the units. Copolymers, terpolymers andhigher polymers of vinylidene fluoride may be made by reactingvinylidene fluoride with one or more monomers from the group consistingof vinyl fluoride, trifluoroethene, tetrafluoroethene, one or more ofpartly or fully fluorinated alpha-olefins such as3,3,3-trifluoro-1-propene, 1,2,3,3,3-pentafluoropropene,3,3,3,4,4-pentafluoro-1-butene, and hexafluoropropene, the partlyfluorinated olefin hexafluoroisobutylene, perfluorinated vinyl ethers,such as perfluoromethyl vinyl ether, perfluoroethyl vinyl ether,perfluoro-n-propyl vinyl ether, and perfluoro-2-propoxypropyl vinylether, fluorinated dioxides, such as perfluoro(1,3-dioxole) andperfluoro(2,2-dimethyl-1,3-dioxole), allylic, partly fluorinatedallylic, or fluorinated allylic monomers, such as 2-hydroxyethyl allylether or 3-allyloxypropanediol, and ethene or propene. Preferredcopolymers or terpolymers are formed with vinyl fluoride,trifluoroethene, tetrafluoroethene (TFE), and hexafluoropropene (HFP).

Preferred copolymers are of VDF comprising from about 71 to about 99weight percent VDF, and correspondingly from about 1 to about 29 percentTFE; from about 71 to 99 weight percent VDF, and correspondingly fromabout 1 to 29 percent HFP (such as disclosed in U.S. Pat. No.3,178,399); and from about 71 to 99 weight percent VDF, andcorrespondingly from about 1 to 29 weight percent trifluoroethylene.

Preferred terpolymers are the terpolymer of VDF, HFP and TFE, and theterpolymer of VDF, trifluoroethene, and TFE, The especially preferredterpolymers have at least 71 weight percent VDF, and the othercomonomers may be present in varying portions, but together theycomprise up to 29 weight percent of the terpolymer.

The polyvinylidene fluoride could also be a functionalized PVDF,produced by either copolymerization or by post-polymerizationfunctionalization, such as KYNAR ADX from Arkema Inc. with graftedmaleic anhydride functionality. KYNAR ADX could be a blend or puregrafted polymer. The use of a functionalized PVDF for the contact layercould be useful in industrial applications where the highest purity isnot a major concern. However, in biopharmaceutical and other applicationrequiring high purity, the functional PVDF is not as useful for directsurface contact, since some of the functional monomers could leach outfrom the PVDF.

When the multi-layer article is composed only of fluoropolymers, atleast two chemically different fluoropolymers must be present. Exampleswould include a PVDF homopolymer inner layer/PVDF copolymer of PVDF andHFP/PVDF homopolymer outer layer; a PVDF inner layer/KYNAR ADX/PVDFhomopolymer outer layer; and a PVDF/HFP copolymer inner layer andPVDF/HFP outer layer where the ratios of PVDF to HFP are different ineach layer.

Non-Fluoropolymer Layer

At least one layer of the multi-layer article is a non-fluoropolymer. Ina preferred embodiment the multi-layer article contains one or morenon-fluoropolymer layers. The non-fluoropolymer layers are preferablycompatible with the fluoropolymer and should be melt-processible.Melt-processible polymers useful in the invention, include, but are notlimited to: polyvinyl chloride (PVC), polymethylmethacrylate (PMMA)homopolymers and copolymers, polyethylene (of all densities),polybutylene, polypropylene, polyamides especially polyamides 6, 11 and12 and the copolyamides thereof, functional polyolefins, thermoplasticolefin (TPO), alkyl(meth)acrylate polymers and copolymers, acrylonitrilebutadiene styrene (ABS) terpolymers, acrylonitrile-styrene-acrylate(ASA) terpolymer, polycarbonate (PC), polyesters, poly(butyleneterephthalate), poly(ethylene terephthalate), MBS copolymers, highimpact polystyrene (HIPS), acrylonitrile/acrylate copolymers, polyethylene terephthalate (PET), acrylonitrile/methyl methacrylatecopolymers, impact modified polyolefins and impact modified PVC, ormixtures thereof. In a preferred embodiment, the non-fluoropolymerlayer(s) is elastomeric. Useful elastomeric polymers are those havingthe ability to return to their original shape when a load is removed.Elastomeric polymers most useful in the elastomeric layer(s) of theinvention are those that can easily be melt-processible. Examples ofuseful elastomeric polymers include, but are not limited to, elastomericpolyamide TPE (thermoplastic elastomer), such as PEBAX (Arkema Inc.);thermoplastic vulcanates (TPV) such as SANTOPRENE (polypropylene-EPDMTPV produced by Advanced Elastomer Systems); thermoplastic olefins (TPO)such as Engage (ethylene-propylene polyolefin elastomer produced by DowChemical); thermoplastic vulcanates (TPV) containing grafted or reactedfunctional groups including maleic anhydride or glycidal methacrylate,such as SANTOPRENE; thermoplastic vulcanates that are polyamide based(PA based) or thermoplastic polyester elastomer based (such as HYTRELproduced by Dupont); acrylate rubbers such as SEBS(styrene-ethylene-butylene-styrene copolymer produced by Shell,thermoplastic polyurethanes (TPU based on polyesters or polyethers inboth aliphatic and aromatic versions); polyester type TPE such asHYTREL; polyesters and copolyesters; polyamides and copolyamide;fluoroelastomers (VITON from Dupont, KYNAR Ultraflex from Arkema Inc),silicones, Neoprene, nitrile rubber, butyl rubber, polyamides,polyolefins such as polyethylene and polypropylene, chlorinated vinyls,such as PVC and flexibilized PVC where the flexibililzed PVC istypically plasticized.

In one embodiment, the non-fluoropolymer layer(s) provides a flexiblearticle. By “flexible”, as used herein, means a multi-layer film of athickness of 100 microns or less can be bent or folded over acylindrical rod having a diameter of 10 mm without destroying thephysical or optical properties of the film. A multi-layer film of up to200 microns can be bent or folded over a cylindrical rod in a diameterof 100 mm without destroying the physical or optical properties of thefilm. The multi-layer article is not flexible if crazing, or otherphysical or optical change occurs during these tests. For a multi-layertube or pipe, “flexible” means that the tube can be bent to a radius of20 times the tube or pipe diameter without the tube collapsing or beingpinched closed.

Barrier Layer

The multi-layer structure may contain at least one barrier layer. Usefulbarrier layers include, but are not limited to ethylene vinyl alcohol(EVOH) and poly(vinyl alcohol) which is fully or partially hydrolyzedpolyvinyl acetate. The barrier layer is preferably present in films,reactors, bags, and other multi-layer structures to improve permeationresistance to CO₂, O₂, H₂O, and other substances. Multi-layer tubing,especially very flexible tubing such as that used in peristolic pumps,may have no extra barrier layer present.

Tie Layers

One difficulty with constructing a multi-layer structure with a PVDF isthat few materials adhere well to PVDF. Adhesion can be aided throughthe use of a functional polymer or a tie layer. The functional polymeror tie layer may also serve as a compatibilizer between polymers whenrecycled in a melt blend. In one embodiment, a functional PVDF, such asmaleic anhydride functional PVDF available as KYNAR ADX from ArkemaInc., can be directly adhered to the PVDF contact layer, and then canadhere to many elastomeric compounds.

A tie layer can also be used to improve adhesion between layers. The tielayer or layers are known in the art, and can be selected depending onthe elastomeric layer, and can include, but are not limited to, one ormore of the following materials: KYNAR ADX, LOTADER (functionalizedpolyethylene from Arkema), OREVAC (functionalized polyethylene orpolypropylene from Arkema), thermoplastic polyurethanes (TPU), CPE(chlorinated polyethylene), functional tie layers (TPO—thermoplasticolefins), polyamides, particularly amine terminated, fluoropolymers,polyolefins, polymethylmetacrilate, and other acrylics. These materialscan also be blended in some cases to make a superior tie layer.

Properties/Construction of the Multi-Layer Film

The multi-layer materials of the invention can be formed in a variety ofways, as known in the art, including but not limited to coextrusion, andlamination, or other process capable of forming a multi-layer material.Single layers to be used in lamination can be formed by extrusion, castfilm, blown film and oriented film.

The multi-layer structure is preferably of high purity, has a highresistance to O₂, CO₂, and H₂O and has little or no leaching into theinterior of the structure (the side in contact with fluids of gases).Ideally the material is also weldable thermally, by radiation, or radiofrequency; can be sterilized; and has good low temperature properties.Sterilization can occur by autoclave (steam sterilization), gammasterilization, radio frequent sterilization, ethylene oxide and otherknown methods.

The multilayer material may be used in a final application withoutmodification, or can be formed into a useful objects such as containers,fittings, tubes, filters, bags, catheters, connectors, filters,membranes, and similar objects. Having a fluoropolymer inner layer, themultilayer articles are especially useful in high purity contactapplications, such as for biological, biomedical, pharmaceutical andchemical contact. Some examples include an IV bag and tubes, or abioreactor used for manufacture or fermentation leading to sera,biologicals, and pharmaceuticals.

A typical disposable manufacturing system is composed of severalcomponents, including:

-   -   1) A bag, serving as the main component of the manufacturing        system and generally made by welding multilayer films together.    -   2) Flexible tubing. One example is a PVDF/TPU flexible tube: the        inner layer being a thin layer (3-500 microns, preferably 15 to        150 microns, and most preferably 25-75 microns) of PVDF and the        thicker (250 to 1500 microns) outer layer being TPU. This tube        is flexible enough to be used directly in peristolic pumps.    -   3) Connectors, impellers and miscellaneous components.        Connectors are welded to the bags and facilitate the connection        of the tubes. These connectors are generally injection molded        from PVDF and are welded to the bags. It is important to note        that the bags have PVDF layer on the exposed surfaces, which        makes direct welding possible. Other components of these        disposable systems such as stirrers and probe gates can also be        injection molded from PVDF.

In general, films used in the invention, and formed into articles suchas bags contain from 2 to 5 or more layers. The overall thickness of thefilm is from 1 to 40 mils and preferably from 3 to 15 mils. In oneembodiment, a bag is made of a PVDF/TPU/EVOH/TPU/PVDF composition,having a high purity fluoropolymer with low surface tension on the innerlayer, the bulk of the structure's volume being TPU with goodflexibility and toughness and also acts as a tie-layer between the PVDFand EVOH. Preferably the TPU is ester based without lubricants. Theweight percent of PVDF is from 10-100 wt %, preferably 10-90 wt %, andmore preferably 25 to 70 wt %, the weight percent of TPU being from 0 to90 wt %, preferably from 10 to 80 wt %, and more preferably from 30 to70 wt %, and the weigh percent of EVOH is from 0 to 40%, preferably 5-30wt %, and more preferably from 5 to 25 wt %. The percentages adding to100%. Some preferred layer thicknesses for this composition in mils(first number is the inner layer) are: 2/2/1/2/1, 1/2/1/2/1, and2/2/1/2/2.

Other useful film constructions include:

-   -   1) PVDF/TPU/EVOH/TPU/copolyester    -   2) PVDF/TPU/EVOH/polyamide    -   3) PVDF/TPU/PVC

Tubes used in the disposable systems could be 2, 3, 4, 5 or more layers.A typical tube would have a two layer PVDF/TPU structure and could haveinside diameters from lass than 1/32″ to over 1″. The thickness of thetube depends on the application and diameter. In the tube structure,PVDF could be from 1% to 99% and preferably from 15 to 40 percent byweight of the tube. In the case of two-layer structure, TPU provides thebalance of the thickness. For the tubes that include EVOH, the balanceis provided by TPU and EVOH.

Process of Recycling

An advantage of the present invention is that the whole disposablemanufacturing system (bag, tube, fittings, impeller, etc) can berecycled, without a need to disassemble various parts before recycling.A typical recycling process involves the following steps.

-   -   1) In most applications, the system is sterilized using        autoclave or radiation before shipping out of the lab. Systems        are gathered and preferably pre-washed.    -   2) The whole system is ground into small pieces or flakes using        a grinding machine. The size of the flakes could be controlled        using various methods but the most common way is by using        screens and sieves. The average size of the flakes is generally        in the order of several mm to facilitate the remaining recycling        steps.    -   3) The flakes are washed using water or a suitable solution.        Metal, paper, ink and other contaminants are separated using        various methods. The material is then dried and stored.    -   4) Flakes are fed into an extruder with intensive mixing        sections. A twin screw extruder is preferable. Using this        process, flakes are converted into pellets suitable for        conversion into a useful article. The compatibility of the        ingredients guarantee enough melt strength and stability for        stranding and pelletizing. In this step, compatibilizers can be        added if necessary. One useful compatibilizer is KYNAR ADX, a        maleic anhydride functionalized PVDF from Arkema Inc.    -   5) In most cases, large quantity of pellets are tumble mixed to        further unify the average composition of the product.    -   6) These pellets are used in thermoforming processes such as in        extruders, injection molding machines and other polymer        processing equipments to create pipes, tubes, films, injection        molded, blow molded or similar articles.

Articles Made of the Recycled Multi-Layer Structures.

A unique feature of the present invention is that compatible melt blendsof recycled materials can be formed from a broad range of ratios offluoropolymer to other components. This is important, since the exactcompositions and ratios of layer compositions influoropolymer-containing disposable multi-layer materials will vary frommaterial to material. As noted above, connectors and impeller will beprimarily PVDF, tubing generally contains little or no barrier layer,and even the bags can vary in composition depending on the process inwhich they were used.

In the recycled melt blend, the weight percent of the components is from1 to 100, preferably 10 to 90, and more preferably 25 to 70 weightpercent fluoropolymer; 0 to 40 and preferably 5 to 25 weight percentbarrier material; and 0 to 90 and preferably 25 to 75 weight percentnon-fluoropolymer material; the total adding to 100 percent. Thefluoropolymer, non-fluoropolymer and bather layer may be of a singlecomposition, or may be a combination of two or more differentcompositions and/or different layers and materials.

In one embodiment, a manufacturing system having a multi-layer bag ofPVDF/TPU/EVOH/TPU/PVDF, plus multi-layer tubing, and single compositionstirrers and connectors is recycles into a melt blend. The weightpercentage of each component is 10 to 100, and preferably 25 to 70weight percent of PVDF; 0 to 90 and preferably 30-70 weight percent TPU;and 0 to 40 weight percent and preferably 5 to 25 weight percent ofEVOH. From 1 to 60 weight percent and preferably 15 to 30 weight percentbased on the total composition of a compatibilizer, such as KYNAR ADXpolymer (a maleic anhydride modified PVDF) could be added to the meltblend before being formed into a final article. KYNAR ADX polymer canhave from 0.1% to 30% and preferably from 0.5% to 10% weight percent ofmaleic anhydride graft or content. A blend of these three materials inthe above range has good melt processing and melt strength behavior andcan easily be converted to films and tubes or injection molded parts.The morphology of the blend exhibits interesting properties. For thesystems with TPU as the continuous phase, EVOH and PVDF exist asseparate dispersed domains. The size of the PVDF particles will be atleast an order of magnitude larger than the EVOH domains. Small domainsof TPU can be seen inside the PVDF region in higher magnifications. FIG.1 shows a micrograph of a 30/60/10 blend of PVDF/TPU/EVOH on weightbasis. For systems with PVDF as the continuous phase, more complexmorphologies including a bull's eye structure of EVOH surrounded by TPUin a matrix of PDVF are observed. Given the density difference betweenPVDF and EVOH and TPU, the system needs to have at least 60 weightpercent of PVDF to have a continuous PVDF phase. A continuous PVDFmorphology has major implications in terms of the improvement of thepermeation and chemical exposure.

The TPU/PVDF/EVOH blend has substantially better fuel exposure andpermeation properties than pure TPU. Exposure of the blend to selectedchemicals shows better chemical properties of the blend compared to TPU.Examples 1 to 3 present these results.

The recycled blend could be used as 100% recycled material, or couldalso be melt-blended with virgin materials to form melt-processed finalarticles. The recycled blend of the invention could also be formed intopellets or powder that could then be transported to a melt-processingmanufacturing site, and formed into useful articles.

Another use for the recycled blend of the invention is as a polymerprocess aid (PPA). The recycled blend could be extruded and cut intopellets, or ground into flakes or powder, and added at low levels with amelt-processible matrix polymer. The recycled blend is used at a levelcalculated to provide from 0.01 to 25 percent, preferably 0.02 to 20percent, and most preferably from 0.05 to 15 percent fluoropolymer byweight in the final blend. The recycled fluoropolymer blend would beuseful as a process aid in a variety of polymer systems, including, butnot limited to polyvinyl chloride (PVC), polycarbonate (PC),polycarbonate/polyester blends, and thermoplastic urethanes (TPU). ThePPA acts to decrease the apparent melt viscosity of the matrix polymer.TPU is especially difficult to melt process due to its stickiness, andthe recycled blend of the invention is especially useful as a processaid with TPU. The fluoropolymer in the recycled blend as a process aidalso reduces the extruder back pressure and torque, reducing thepossibility of melt fracture and making the sizing of articles easier.An advantage of using the recycled blend of the invention as a processaid, is that not only is the melt-viscosity improved, but the additionof even these low levels of fluoropolymer should provide improvedchemical resistance, weather resistance, reduction of surface friction,and improvement of other surface properties.

Example 1

Multilayer films were extruded with three different materials having afive-layer construction. This construction is based on KYNAR 2800 (PVDFcopolymer with HFP from Arkema Inc.). Table 1, below, describes thefilm.

TABLE 1 KYNAR 2800 Based Multi-Layer Film KYNAR ELASTOLLAN EVALCAELASTOLLAN KYNAR 2800-20 C85A10 H171b C85A10 2800-20 30 micron 30 micron15 micron 30 micron 60 micron

The film was ground down to ⅛″ flakes. Per weight basis the blend hasapproximately 62% KYNAR 2800, 30% ELASTOLLAN C85A10 (from BASF), and 8%EVALCA H171b (from Kuraray). These flakes were then pelletized on a 18mm Leistritz co-rotating twin screw extruder. The screw used wasspecially designed for intensive mixing. The KYNAR 2800 basedmulti-layer film pelletized very easily. The pellets were then dried at60° C. for a minimum of 2 hours in a vacuum drier. After drying, thepellets were injection molded into ASTM D 638 Type I and IV tensilebars. The bars were tested for tensile and elongation following ASTM D639. The Type I bars were converted to ASTM D 265 impact bars. The barswere notched and tested at −40° C. and −60° C. in accordance with ASTM D265 notched impact. Table 2 illustrates the tensile, elongation, andimpact physical properties

TABLE 2 Tensile, Elongation, and Impact Physical Properties 10% 10%Slope Slope Automatic −40° C. −60° C. Threshold Stress at ThresholdStrain at Young's Impact Impact Stress Break Strain Break ModulusResistance Failure Resistance Failure Material (psi) (psi) (%) (%) (psi)(ft * lbf/in) Mode (ft * lbf/in) Mode KYNAR 1445 2456 19.8 467.5 193222.519 Partial 5.812 Complete 2800 Multi- Layer Film Regrind KYNAR 38133870 9.7 367.3 106074 2.798 Complete 1.200 Complete 2800 ControlELASTOLLAN 522 1467 39.5 752.3 2505 — No Break — No Break C85A10 Control

The parts were then exposed to Fuel CE10a at 40° C. Weight and Lengthchange measurements were recorded. Table 3 illustrates the weight andlength change for 74 days of exposure time.

TABLE 3 Weight and Length Change for Fuel Exposureat 40° C. % WeightMaterial Gain % Length Gain 2800 Multi-Layer 17.78 6.14 Film RegrindKYNAR 2800 2.62 3.16 Control ELASTOLLAN 47.59 17.42 C85A10 Control

The parts were exposed to HCl (3n), Sulfuric Acid (>20%), Bleach (50%),Ethylene Glycol (50%), Sodium Hydroxide (>20%) at 23° C. Weight gainmeasurements were recorded. Table 4 illustrates the weight change for 45days of exposure.

TABLE 4 Chemical Exposure at 23° C., % Weight Gain Ethyl- SodiumSulfuric ene Hydrox- Acid, Bleach, Glycol, ide, Material HCl, 3n 25% 50%50% 30% 2800 Regrind 0.35% 0.14% 0.89% 0.82% 0.53% Film 2800 Control0.05% 0.00% 0.03% 0.01% 0.00% ELASTOLLAN −5.69%, −3.48%, 1.15% 0.82%−0.62%  Control cracked cracked

The pellets were dried and converted into tubes using a 1.5″ DavisStandard single screw extruder. The tubes processed very easily. Thetube had a ⅜″ outside diameter with a 0.040″ wall thickness. The tubeshad a very smooth surface finish on the outside as well as the inside.The tubes were tested for permeation using Fuel CE10a at 40° C. Table 5illustrates the normalized permeation results after 55 days of testing.

TABLE 5 Normalized Permeation in Fuel CE10a at 40° C. NormalizedPermeation Material Fuel (g * mm/m{circumflex over ( )}2/day) 2800Multi-Layer Film Regrind CE10a 714.52 KYNAR 2800 Control CE10a 1.60ELASTOLLAN Control CE10a 1466.60

The pellets were dried and converted to a 7 mil film using a 1″ Killionextruder and a coat-hanger film die. The film processed very well. Table6 shows the tensile and elongation properties in machine and transversedirections.

TABLE 6 Tensile and Elongation Properties 10% Slope 10% Slope Automatic1% Stress at Strain at Threshold Threshold Stress at Strain at Young'sSecant Yield Yield Stress at Strain at Break Break Modulus ModulusThickness Direction (psi) (%) Yield (psi) Yield (%) (psi) (%) (psi)(psi) (in) Machine 4632 47.3 4373 27.8 4544 55.3 32650 32352 0.00787Transverse 1243 26.1 1173 16.3 1009 97.5 17859 17944 0.00757

Graves tear testing properties are shown in Table 7 in machine andtransverse directions.

TABLE 7 Graves Tear Properties Extension Transverse at Tear MaximumMaximum Resistance Thickness Direction Load (gf) Load (in) (gf/mil) (in)Machine 1188.61 0.067 156.99 0.0076 Transverse 2629.01 0.085 358.270.0073

Example 2

Multilayer films were extruded with three different materials having afive-layer construction. This construction is KYNAR 2500 based. Table 8,below, describes the film.

TABLE 8 KYNAR 2500 Based Multi-Layer Film KYNAR ELASTOLLAN EVALCAELASTOLLAN KYNAR 2800-20 C85A10 H171b C85A10 2500-20 30 micron 30 micron15 micron 30 micron 60 micron

The film was ground down to ⅛″ flakes. Per weight basis the blend hasapproximately 62% KYNAR 2800, 30% ELASTOLLAN C85A10, and 8% EVALCAH171b. These flakes were then pelletized on a 18 mm Leistritzco-rotating twin screw extruder. The screw used was specially designedfor intensive mixing. The 2500 based multi-layer film pelletized veryeasily. The pellets were then dried at 60° C. for a minimum of 2 hoursin a vacuum drier. After drying, the pellets were injection molded intoASTM D 638 Type I and IV tensile bars. The bars were tested for tensileand elongation following ASTM D 639. The Type I bars were converted toASTM D 265 impact bars. The bars were notched and tested at −40° C. and−60° C. in accordance with ASTM D 265 notched impact. Table 9illustrates the tensile, elongation, and impact physical properties, asmeasured by ASTM D 639.

TABLE 9 Tensile, Elongation, and Impact Physical Properties 10% 10%Slope Stress Slope Strain Automatic −40° C. −60° C. Threshold atThreshold at Young's Impact Impact Stress Break Strain Break ModulusResistance Failure Resistance Failure Material (psi) (psi) (%) (%) (psi)ASTM (ft * lbf/in) Mode (ft * lbf/in) Mode 2500 1457 3970 17.9 884.817433 D 256 2.519 No break 5.812 Complete Multi- Layer Film RegrindKYNAR 3813 3870 9.7 367.3 106074 D 256 2.798 Complete 1.2 Complete 2800Control Elastollan 522 1467 39.5 752.3 2505 D 256 — No Break — No BreakC85A10 Control

The parts were then exposed to Fuel CE10a at 40° C. Weight and Lengthchange measurements were recorded. Table 10 illustrates the weight andlength change for 74 days of exposure time.

TABLE 10 Weight and Length Change for Fuel Exposure at 40° C. Material %Weight Gain % Length Gain 2500 Multi-Layer Film Regrind 16.70 6.14 KYNAR2800 Control 2.62 3.16 ELASTOLLAN C85A10 Control 47.59 17.42

Example 3

Considering that the recycled material could include tubes and/orconnectors that have different ratios of ELASTOLLAN C85A10 to KYNAR2800. We ran a series of tests and varied the ratios of the ELASTOLLANC85A10, KYNAR 2800, and EVALCA H171b. The series of tests showed goodproperties of the blends regardless of the composition. Table 11 showsthe compositions tested and Table 12 shows the physical properties ofeach composition as measured by ASTM D 639 and impact resistance asmeasured by ASTM 256.

TABLE 11 Compositions of each blend Composition (Wt. %) Composition(Vol. %) KYNAR ELASTOLLAN EVALCA KYNAR ELASTOLLAN EVALCA Blend 2800C85A10 H171b 2800 C85A10 H171b 1 100 0 0 100 0 0 2 75 15 10 67 20 13 360 30 10 50 37 12 4 30 60 10 22 67 11 5 15 75 10 11 79 11 6 0 100 0 0100 0

TABLE 12 Physical Properties of each Composition 10% 10% Slope StressSlope Strain Automatic −40° C. −60° C. Threshold at Threshold at Young'sImpact Impact Stress Break Strain Break Modulus Resistance FailureResistance Failure Blend (psi) (psi) (%) (%) (psi) (ft * lbf/in) Mode(ft * lbf/in) Mode 1 3813 3870 9.7 367.3 106074 2.798 Complete 1.2Complete 2 3043 4907 9.3 581.1 89810 4.799 Complete 3.032 Complete 32035 5070 15.8 821.7 30637 — No Break 5.457 Complete 4 1111 2436 25868.9 8285 — No Break 2.61 Partial 5 854 3873 27.3 888.6 2755 — No Break— No Break 6 522 1467 39.5 752.3 2505 — No Break — No Break

Chemical exposure was performed on some of these blends. They wereexposed to HCl (3n), Sulfuric Acid (25%), Bleach (50%), Ethylene Glycol(50%), Sodium Hydroxide (30%) at 23° C. for 45 days. Weight change isbeing observed after 45 days, Table 13 shows the results of weightchange.

TABLE 13 Chemical Exposure at 23° C., % Weight Change Sulfuric EthyleneSodium Acid, Bleach, Glycol, Hydroxide, Material HCl, 3n 25% 50% 50% 30%2800 Control 0.05 0.00 0.03 0.01 0.00 50/40/10 0.33 0.21 1.39 1.24 −0.66ELASTOLLAN −5.69, −3.48, 1.15 0.82 −0.62 Control cracked cracked

Example 4

We added 20% by weight of KYNAR ADX 285, which is PVDF with maleicanhydride functionality included in the chain, to a material blend as acompatibilizer. The KYNAR ADX blend is very similar to the KYNAR 2800based multi-layer film in Example 1 structure, but with the addition ofKYNAR ADX 285. Table 14, describes the composition of the materials inthe blend.

TABLE 14 Weight % Composition of Material KYNAR ELASTOLLAN EVALCAMaterial 2800 ADX285 C85A10 H171b 2800 Multi-Layer 64 0 29 7 FilmRegrind KYNAR ADX 40 20 32 8 Blend

The compounds were injection molded into tensile ASTM D 639 type Itensile bars. Tensile and Elongation as well as notched cold temperatureimpact was performed on these bars. The physical properties are shown inTable 15 as measured by ASTM D 639 and ASTM 256.

TABLE 15 Physical Properties Comparing to the Addition of KYNAR ADXAutomatic −40° C. 10% Slope Stress at 10% Slope Strain at Young's ImpactThreshold Break Threshold Break Modulus Resistance Failure MaterialStress (psi) (psi) Strain (%) (%) (psi) (ft * lbf/in) Mode 2800 Multi1457 3970 17.9 884.8 17433 — 70% No Layer Film Break Regrind 2.519 30%Partial 40/20/32/8 2118 5749 18.2 664 29229 — 100% No Break

Chemical exposure testing was performed for both materials for durationof 45 days at 23° C. Table 16 illustrates the results.

TABLE 16 Chemical Exposure Testing, % Weight Change Ethylene Sodium HCl,Sulfuric Bleach, Glycol, Hydroxide, Material 3n Acid, 25% 50% 50% 30%KYNAR 2800 0.35% 0.14% 1.89% 0.82% 0.53% Regrind Film 40/20/32/8 0.49%0.30% 1.05% 0.84% −0.16%

Example 5 Comparative

A known multi-layer structure consists of LOTADER AX8840 (Arkema Inc.),HDPE DOW DGDB-2480 NT, and KYNAR ADX120 (Arkema Inc.). For example afilm of this structure that is 10 mils thick would have a 1.5 mil layerof LOTADER, 3.5 mils of HDPE, and 5 mils of KYNAR. When calculated byweight this is equivalent to 10% LOTADER, 25% HDPE, and 65% KYNAR ADX.

A 10/25/65 by weight blend of LOTADER AX8840, HDPE, and KYNAR ADX wasmade on a 18 mm Leistritz twin screw extruder with a screw designed forintensive mixing. The blend was injection molded into ASTM D 638 type Itensile bars and ASTM D 256 impact test specimens and tested at 23° C.Below are the results for the mechanical testing as compared to thecontrol of HDPE and KYNAR.

TABLE 17 Mechanical Properties Weight % Loading Elongation Impact KYNARElongation at at Break Strength LOTADER HDPE ADX 120 Yield (%) (%)(ftlb/in) 0 100 0 9.9 17.6 2.91 0 0 100 8.7 52.8 1.45 10 25 65 8.6 9.91.44

As can be seen, the properties of the blend are below the properties ofthe controls. Moreover, severe craze, whitening and crack would occurwhen an extruded strand or tensile bars are simply bent.

The next step in the evaluation is to make film on a three roll stackcast film line. Making quality film was not possible. The blend lackedmelt strength and would tear very easily. Severe gross phase separationand plate out was also observed during the process.

In this case, both the mechanical properties and the processibility ofthe blend are worse than the individual components.

Example 6 Nylon Example

Two films were produced using the same components; KYNAR 2800,ELASTOLLAN C85A10, EVALCA H171b, and BESNO TL. The first film was amultilayer film of weight percent and thickness shown below and thesecond film was a single layer film having identical weight percents ofthe contents in the multilayer. The multilayer film is transparent; themelt blended film is opaque. Pelletization of the blend andmanufacturing of the blended film was performed without any processingissues. Below is a description of the structure.

TABLE 18 Film Structures KYNAR ELASTOLLAN EVALCA BESNO 2800 C85A10 H171bTL CG 5C 08-859 Film Weight % 48% 16% 8% 28% Layer Thickness 2 1 1 2(mils) Melt Blended Film Nylon Blended Film 48% 16% 8% 28%

The two films were made of similar thickness and tested for tensile andgraves tear in the machine and transverse directions. Below are theresults.

TABLE 19 Tensile Properties in Machine Direction Machine DirectionStress Automatic Film at Strain at Stress at Strain at Young'sIdentification Yield Yield Break Break Modulus Thickness # (psi) (%)(psi) (%) (psi) (in) CG 5C 3886 5.8 7399 475.5 134052 0.006 08-859 FilmNylon 2236 9.4 4001 387.0 68909 0.006 Blended Film

TABLE 20 Tensile Properties in Transverse Direction Transverse DirectionStress Automatic Film at Strain at Stress at Strain at Young'sIdentification Yield Yield Break Break Modulus Thickness # (psi) (%)(psi) (%) (psi) (in) CG 5C 3960 5.3 6799 470.9 143314 0.006 08-859 FilmNylon 1008 2.3 1926 347.4 63701 0.006 Blended Film

TABLE 21 Tear Resistance in Machine Direction Machine Direction MaximumExtension at Tear Load Maximum Resistance Thickness Film Identification# (gf) Load (in) (gf/mil) (in) CG 5C 08-859 Film 2886 0.108 450 0.006Nylon Blended Film 1285 0.019 196 0.007

TABLE 22 Tear Resistance in Transverse Direction Transverse DirectionExtension at Tear Maximum Maximum Resistance Film Identification # Load(gf) Load (in) (gf/mil) Thickness (in) CG 5C 08-859 Film 2503 0.195 4820.005 Nylon Blended Film 2668 0.239 409 0.007

1. A melt processible polymer composition comprising a compatible meltblend formed from one or more recycled multi-layer articles, whereinsaid multi-layer article comprises at least one melt-processiblefluoropolymer layer.
 2. The polymer composition of claim 1, wherein saidmulti-layer article further comprises at least one other layercomprising a melt-processible fluoropolymer having a different chemicalcomposition form the first fluoropolymer layer.
 3. The polymercomposition of claim 1, wherein said at least one melt-processiblefluoropolymer layer comprises a polyvinylidene fluoride (PVDF)homopolymer or copolymer.
 4. The polymer composition of claim 2, whereinall fluoropolymer layers consist of a PVDF homopolymer or copolymer. 5.The polymer composition of claim 1, wherein said multi-layer articlefurther comprises at least one non-fluoropolymer layer.
 6. The polymercomposition of claim 5, wherein at least one non-fluoropolymer layer isselected from the group consisting of TPE (thermoplastic elastomer);thermoplastic vulcanates (TPV); thermoplastic olefins (TPO);thermoplastic vulcanates (TPV) containing grafted or reacted functionalgroups; thermoplastic vulcanates that are polyamide based (PA based);thermoplastic vulcanates that are thermoplastic polyester elastomerbased; acrylate rubbers; thermoplastic polyurethanes (TPU) based oneither polyesters or polyethers; polyesters and copolyesters; polyamidesand copolyamides; silicones; neoprene; nitrile rubber; butyl rubber;polyamides, polyolefins; and chlorinated vinyls.
 7. The polymercomposition of claim 1, wherein said multi-layer article furthercomprises at least one barrier layer.
 8. The polymer composition ofclaim 7, wherein said barrier layer is ethylene vinyl alcohol (EVOH) orpoly(vinyl alcohol).
 9. The polymer composition of claim 1 comprising 1to 100 weight percent fluoropolymer, 0 to 40 weight percent of a barrierpolymer, and 0 to 99 weight percent of a non-fluoropolymer, the totaladding to 100 percent.
 10. The polymer composition of claim 9 comprising20 to 90 weight percent fluoropolymer, 5 to 25 weight percent of abarrier polymer, and 25 to 75 weight percent of a non-fluoropolymer, thetotal adding to 100 percent.
 11. The polymer composition of claim 10comprising 25 to 70 weight percent fluoropolymer, 5 to 25 weight percentof a barrier polymer, and 25 to 75 weight percent of anon-fluoropolymer, the total adding to 100 percent.
 12. The polymercomposition of claim 1, wherein said recycled multi-layer article(s)comprise at least one disposable manufacturing system used in biomedicalor pharmaceutical production.
 13. The polymer composition of claim 1,wherein said polymer composition further comprises, in addition to saidrecycled multi-layered articles from 5 to 50 weight percent of one ormore other melt-processible polymers compatible with said recycledmulti-layered articles.
 14. The polymer composition of claim 1comprising polyvinylidene fluoride (PVDF) homopolymer or copolymer, andthermoplastic polyurethane (TPU).
 15. The polymer composition of claim14, further comprising ethylene vinyl alcohol (EVOH) barrier polymer.16. A polymer article formed by a heat processing operation comprisingthe polymer composition of claim
 1. 17. The polymer article of claim 16,wherein said polymer composition comprises the recycled melt blend as aprocess aid in a matrix polymer, wherein the fluoropolymer weightpercent in the article is from 0.05 to 20 weight percent.
 18. Thepolymeric article of claim 17, wherein said matrix polymer is selectedfrom the group consisting of a polyvinyl chloride (PVC), polycarbonate(PC), polyamide or copolyamide, polycarbonate/polyester blends,thermoplastic urethanes (TPU) and polyolefins.
 19. A process for forminga polymeric article from a recycled multi-layer structure comprising thesteps of a. forming a multi-layer article, having each layer adhered tothe adjoining layer(s), wherein said multi-layer structure comprises aninner fluoropolymer layer, and at least one other layer chemicallydifferent from the fluoropolymer inner layer, b. washing and/orsterilizing the multi-layer structure c. grinding the washed and/orsterilized multi-layer structure into small pieces or flakes; d.cleaning the pieces or flakes to remove non-polymeric materials andother contaminants; e. Optionally screening or sizing the flakes orpieces, and regrinding if needed to obtain the desired average particlesize; f. mixing or blending the flakes or small particles; g. meltingthe flakes or small particles h. extruding the melted flakes or smallparticles into pellets directly into final articles; and i.thermoforming the pellets into final articles.
 20. The process of claim19, wherein the multi-layer of step a) further comprises a barrier layerof ethylene vinyl alcohol (EVOH) or poly(vinyl alcohol) (PVOH), and atleast one elastomeric non-fluoropolymer layer.